Electrical connector

ABSTRACT

An electrical connector includes two substantially L-shaped sections composed of an insulating material. One of the sections if formed with bosses having central openings for supporting intermediate portions of terminals. The L-shaped sections are joined together after portions of the terminals have been assembled within the bosses so that end portions of the terminals extend from outer faces of the joined sections. The ends of the terminals extending from one face of the joined sections can be connected to a circuit such as a printed circuit. The opposite ends of the terminals can then be connected, for example by wirewrap connections, to various external circuits.

United States atent Baluck [54] ELECTRICAL CONNECTOR [21] Appl.N0.: 41,292

[52] US. CL ..339/I56 R, 339/17 LC [51] Int. Cl ..H05c 1/06 [58] FieldofSearch ..339/l7 L, l7LC,l7LM,l7M

339/17 C, 47, 49 R, 154, I56, 176 R, 176 M, 176 MP, 176 MP, 196, 198 R, 198 C, 198 6,198 GA, 198 H.210

[56] References Cited FOREIGN PATENTS OR APPLICATIONS l,487,5 l 8 4/1969 Germany ..339/l56 R Mar. 14, 1972 Primary Examiner-Marvin A. Champion Assistant ExaminerLawrence J. Staab Attorney-W. M. Kain, R. P. Miller and Don P. Bush [5 7] ABSTRACT An electrical connector includes two substantially L-shaped sections composed of an insulating material. One of the sections if formed with bosses having central openings for supporting intermediate portions of terminals. The L-shaped sections are joined together after portions of the terminals have been assembled within the bosses so that end portions of the terminals extend from outer faces of the joined sections. The ends of the terminals extending from one face of the joined sections can be connected to a circuit such as a printed circuit. The opposite ends of the terminals can then be connected, for

example by wire-wrap connections, to various external circuits.

5 Claims, 6 Drawing Figures PATENTEUHAR 14 I972 sum 1 OF 2 lNVENTOR E M BALUCK PATENTEUMAR 14 I972 SHEET 2 [1F 2 ELECTRICAL CONNECTOR BACKGROUND OF THE INVENTION l. Field of the Invention This invention relates to an electrical connector and more particularly relates to an electrical connector which supports a plurality of terminals for interconnecting separate circuits.

2. Description of the Prior Art In various types of electrical systems, a plurality of circuits are interconnected to facilitate operation of the circuits. Frequently, some of the circuits are preassembled in a substantially self-contained package. Circuits of this type would include printed wiring circuits which have circuit components assembled with the printed wiring. Since the circuits are selfcontained on a substrate, some means must be provided for connecting the self-contained circuits to circuits externally of the package.

Generally, the configuration of terminals used with connectors which facilitate connection between printed wiring circuits and other circuits are preassembled with a support member composed of an insulating material. Areas within the member, which must be'open to permit the assembly of the terminals with the member, are then filled with a fluid insulating material. The fluid insulating material is subsequently cured to encapsulate intermediate portions of the terminals whereby the terminals are unreleasably supported within a composite insulating block formed by the support member and the cured insulating material.

A connector of this type requires a multistep operation in which portions of the terminals are subjected to considerable heat. In addition, the insulating block is a substantially solid mass of insulating material. If the block is required to support many terminals, the weight of the block becomes a significant factor particularly when the block is to be attached to the rather thin substrate which supports the printed circuits and associated components. Further, the cost of encapsulation to form a substantially solid block also becomes a significant factor of the connector assembly.

Another type of connector includes a one-piece block composed of an insulating material and formed with passageways to receive one leg of each of a plurality of terminals. Other portions of the terminals are not confined and could become detached from the block even after the terminals are assembled with and connected to associated circuits.

SUMMARY OF THE INVENTION It is, therefore, an object of the invention to provide a new and improved electrical connector.

Another object of the invention is the provision of a new and improved electrical connector which is lightweight and supports a plurality of terminals at a relatively low cost.

Still another object of the invention is the provision of a new and improved electrical connector which supports a plurality of terminals in such a manner that the terminals are confined from movement relative to an insulating support of the connector.

A further object of the invention is the provision of a new and improved electrical connector which can be assembled with a self-contained circuit such as a printed wiring assembly having components attached thereto.

An electrical connector illustrating certain principles of the invention may include a pair of complementarily shaped elements composed of an insulating material and joined to form an enclosure. At least one of the elements is formed with a structure which is located within the enclosure for supporting an intermediate portion of a terminal. Terminal ends extend from outer walls of the joined elements to facilitate connections thereto.

BRIEF DESCRIPTION OF THE DRAWINGS Other objects and advantages of the present invention will be apparent from the following detailed description when considered in conjunction with the accompanying drawings in which:

FIG. 1 is a partial perspective view with parts broken away for clarity showing an electrical connector embodying certain principles of the invention and a printed wiring board aligned for assembly with the connector;

FIG. 2 is a perspective view showing one type of terminal included in the electrical connector of FIG. 1;

FIG. 3 is a perspective view showing another type of terminal included in the electrical connector of FIG. 1;

FIG. 4 is a partial perspective view showing unassembled portions of terminal supporting members of the electrical connector of FIG. 1;

FIG. 5 is a sectional view taken along line 5-5 of FIG. 1 showing the terminals of FIGS. 2 and 3 assembled with the terminal supporting members of FIG. 4, and

FIG. 6 is a perspective view showing a packaged electronic switch having printed wiring interconnections between components of the switch and electrical connectors of the type illustrated in FIGS. 1, 4 and 5.

DETAILED DESCRIPTION Referring to FIG. 1, there is illustrated an electrical connector, designated generally by the numeral 11. The electrical connector 11 includes a L-shaped member, designated generally by the numeral 12 and a substantially L-shaped member, designated generally by the numeral 13. The members 12 and 13 are composed of a suitable thermoplastic material such as polysulfone.

The electrical connector 11 also includes a first plurality of terminals, designated generally by the numeral 16, and a second plurality of terminals, designated generally by the numeral 17. The terminals 16-16 and 1717 are assembled with and supported by the members 12 and 13 which are joined to form a support means.

As further illustrated in FIG. 1, a printed wiring board, designated generally by the numeral 18, is positioned to be assembled with the electrical connector 11. One end of each of the terminals l6l6 and 17-17 will be assembled with and subsequently solder-connected to land areas l919 of printed circuits 20-20 on the board 18.

Referring now to FIG. 2, there is illustrated one of the terminals 16- 16 which includes a first end portion 21, a curved intermediate section 22 and a second end portion 23. Referring now to FIG. 3, there is illustrated one of the terminals l7--17 which is generally L-shaped and includes a first end portion 24 and a second end portion 26. The first end portions 21 and 24 of the terminals 16 (FIG. 2) and 17 (FIG. 3), respectively, are fonned to receive wire-wrap connections to external circuits (not shown). The second end portions 23 and 26 of the terminals 16 and 17, respectively, are formed to be inserted through associated openings 2727 (FIG. 1) formed in the printed wiring board 18 generally centrally of the land areas 19-19 of the printed circuits 20-20.

Referring now to FIG. 4, there is illustrated the L-shaped member 12 separated from the substantially L-shaped member 13. The longitudinal edge of one wall 28 of the L- shaped member 12 is formed with a ledge 29. The longitudinal edge of another wall 31 of the L-shaped member 12 is formed with a ledge 32. A plurality of openings 3333 are formed through selected locations in the wall 28 to facilitate the positioning of the end portions 2323 and 2626 of the terminals l6 l6 and 1717, respectively, therethrough.

The longitudinal edge of one wall 34 of the substantially L- shaped member 13 is formed with a shoulder 36. The longitudinal edge of another wall 37 of the substantially L-shaped member 13 is formed with a shoulder 38. The substantially L- shaped member 13 is formed with a longitudinal extension 39 which is in the plane of the wall 34 and is joined to the junction of the walls 34 and 37.

A plurality of parallel, spaced support bosses 41-41 extend outwardly from the inner surface of the wall 34 and along the inner surface of the wall 37 of the substantially L-shaped member 13. Each of the bosses 4141 is formed centrally with an opening 40 (FIG. 5) which also extends through the adjacent portion of the wall 34. The opening 40 of each of the bosses 41-41 is of sufficient size to permit the end portion 21 (FIG. 2) of the terminal 16 to be inserted therethrough to a position as viewed in FIGS. 4 and 5.

A plurality of notches 42-42 are formed in the inner surface of the wall 34 along the edge of the wall and are located adjacent to associated ones of the bosses 41-41. The notches 42-42 provide a guide seat for a portion of the terminals 16-16 and insure that the end portion 23 of each of the terminals can be aligned subsequently with the associated opening 33 formed in the wall 28 of the L-shaped member 12.

Another plurality of spaced, parallel bosses 43-43 extend in cantilever from the inner surface of the wall 34 and are adjacent to the spaces between the bosses 41-41. Each of the bosses 43-43 is formed centrally with an opening 44 (FIG. 5) which extends through an adjacent portion of the wall 34. A guide slot 45 is formed in the free end of each of the bosses 43-43 and communicates with the opening 44 formed in the same boss. The opening 44 of each of the bosses 43-43 is of sufficient size to permit the end portion 24 (FIG. 3) of the terminal 17 to be inserted therethrough. In addition, the slot 45 of each of the bosses 43-43 permits the end portion 26 of the terminal 17 to be moved to a position for subsequent alignment with an associated one of the openings 33-33 formed in the wall 28 of the L-shaped member 12.

After the terminals 16-16 and 17-17 have been assembled with the substantially L-shaped member 13 in the manner previously described, the L-shaped member 12 is positioned adjacent to the assembled terminals and substantially L- shaped member 13. If each of the terminals 16-16 and 17- 17 have been inserted property into the openings 40 and 45 of the associated bosses 41-41 and 43-43, respectively, the end portions 23-23 and 26-26 of the terminals are alignable with associated openings 33-33 in the L-shaped member 12.

The L-shaped member 12 and the substantially L-shaped member 13 are moved relatively toward each other so that the end portions 23-23 and 26-26 of the terminals 16-16 and 17-17, respectively, are inserted through the associated openings 33-33 of the member 12 as illustrated in FIG. 5. In addition, the ledges 29 and 32 of the L-shaped member 12 seat on the shoulders 36 and 38, respectively, of the substantially, Lshaped member 13 and the free end of each of the bosses 43-43 abuts an adjacent portion of the inner surface of the wall 31 of the member 12. In addition, the inner surface of the wall 31 of the member 12 is sufficiently close to the adjacent portions of each of the terminals 16 and 17 to prevent the terminals from being flexed when wire-wrap connections are subsequently placed on the end portions 21 and 24, respectively, of the terminals.

Thereafter pressures, such as ultrasonic forces, are applied to at least one of the members 12 and 13 in such a way that the free end of each of the bosses 43-43 is joined to the adjacent abutting portion of the inner surface of the wall 31 of the member 12. It is noted that other methods, for example, adhesive bonding, could be used tojoin the members 12 and 13.

Referring now to FIG. 6, there is illustrated a packaged electronic switch, designated generally by the numeral 46, which includes a metallic shunt plate 47 and a plurality of precision-wound coils 48-48 similar to the type of coil arrangement described in US. Pat. No. 3,45 l ,633 which issued to J. D. Markham and C. R. Sanders on June 24, I969, The switch 46 also includes printed wiring boards 18-18 on opposite sides thereof which facilitate the wire strapping of sealed contacts (not shown) located centrally of the coils.

In the operation of the electronic switch 46, the opening and closing of the sealed contacts are controlled by pulsing selectively the coils 43-48. The operation of the contacts can then be used to control facilities of external circuits (not shown). The electrical connectors 11-11 are assembled with the shunt plate 47 and the printed wiring boards 18-18 and provide an interconnecting facility between the sealed contacts and the external circuits. The end portions 23-23 and 26-26 of the terminals 16-16 and 17-17 of the connectors 11-11 are inserted through the openings 27-27 formed in the boards 18-18 and are solder-connected to the land areas 19-19 which surround the openings. The end portions 21 and 24 of the terminals 16-16 and 17-17 can then be connected to the external circuits by wire-wrap or other suitable connectionsv Referring again to FIG. 1, portions of the connector 11 are formed with cylindricallike relief openings 49-49 which facilitate the assembly of the connector and printed wiring boards 18-18 with the shunt plate 47 (FIG. 6). In addition, small screws 51-51 (FIG. 6) are used to secure the printed wiring board 18 with the connector 11.

The connector 11 is a lightweight, inexpensive, rigidly assembled, interconnecting facility which is easily and quickly assembled. The use of the connector 11 is not limited to the use shown in FIG. 6 but can be used to interconnect other types and configurations of circuits. In addition, the configuration of the connector 11 could be altered to accommodate a different complementary environment without diminishing the advantages thereof. The enclosure provided by the joined L-shaped members 12 and 13 and the location and structure of the bosses 41-41 and 43-43 facilitate the confining of the terminals 16- 16 and 17-17 to prevent movement of the terminals within the enclosurev What is claimed is:

1. An electrical connector, which comprises:

a first preformed insulating member having at least an outer surface and an inner surface;

a plurality of terminals;

means formed on the inner surface of the first insulating member for supporting intermediate sections of the terminals which are assembled with the first member so that one end portion of each terminal extends from the outer surface of the first insulating member and the opposite end portion of each terminal extends from the means for supporting the terminals;

a second preformed insulating member having at least an outer surface and an inner surface and structure complementary to the first insulating member, the second insulating member being assembled with the first insulating member and the terminals to restrict the intermediate sections of the terminals to a position within the means for supporting and to support the opposite end portions of the terminals which extend through the inner surface and beyond the outer surface of the second insulating member to provide interconnecting terminations externally of the assembled first and second insulating members; and

means for engaging the opposite end portions of at least some of the terminals to guide the opposite end portions of the terminals into a position of alignment with and for assembly with the second insulating member when the second insulating member is assembled with the first insu' lating member and the terminals.

2. The electrical connector as set forth in claim 1, wherein the means for supporting intermediate portions of the terminals includes a plurality of bosses which are formed integrally with the first insulating member and extend from the inner surface of the first member.

3. The electrical connector as set forth in claim 1, wherein the means for engaging the opposite end portions of the terminals includes a plurality of notches formed selectively in the inner surface of the first insulating member for receiving the opposite end portions of at least some of the terminals to align the opposite end portions in a position for assembly with the second insulating member.

4. An electrical connector, which comprises:

a first L-shaped member composed of an insulating materia second L-shaped member composed of an insulating material;

each of said L-shaped members having first and second walls with each wall having an inner and an outer surface;

the first wall of each of the L-shaped members being formed with a plurality of openings;

a first plurality of bosses extending perpendicularly from the inner surface of the first wall of the first L-shaped member and along the inner surface of the second wall of the first member;

a second plurality of bosses extending perpendicularly from the inner surface of the first wall of the first insulating member;

each of the first and second plurality of bosses formed with an opening which is an axial continuation of one ofthe openings formed in the first wall of the first L-shaped member;

a first plurality of guide slots formed in the inner surface of the first wall of the first L-shaped member aligned with and spaced from the first plurality of bosses;

a second plurality of guide slots formed in the second plurality of bosses in communication with the openings of the bosses;

a first plurality of terminals, each of the first plurality of terminals having an intermediate portion inserted into the opening of an associated one of the first plurality of bosses with one end portion extending through and from an associated one of the openings formed in the first wall of the first L-shaped member and with the other end having a portion thereof positioned within one of the first plurality of guide slots;

a second plurality of terminals, each of the second plurality of terminals having intermediate portions inserted into the opening of an associated one of the second plurality of bosses with one end portion extending through and from an associated one of the openings formed in the first wall of the first L-shaped member and with the other end having a portion thereof positioned within one of the second plurality of guide slots;

the other ends of the first and second plurality of terminals being aligned in a desired arrangement by the positioning of the portion thereof within the first and second plurality of guide slots, respectively, and

the second L-shaped member being assembled complementarily and secured with the first L-shaped member with the other ends of the aligned terminals being inserted through associated ones of the plurality of openings formed in the first wall of the second Lshaped member and the inner surface of the second wall of the second L- shaped member being positioned adjacent to ends of the first and second plurality of bosses to retain the first and second plurality of terminals in the assembled position.

5. An electrical connector, which comprises:

first and second complimentarily formed, L-shaped insulating members, each member having first and second walls with a plurality of openings formed in the first walls thereof;

a plurality of bosses extending perpendicularly from an inner surface of the first wall of the first L-shaped member and along an inner surface of the second wall of the first member;

each of the plurality of bosses formed with an opening which is an axial continuation of one of the openings formed in the first wall of the first L-shaped member;

a plurality of guide notches formed in the inner surface of the first wall of the first L-shaped member aligned with and spaced from the plurality of bosses;

a plurality of terminals, each of the plurality of terminals having an intermediate section inserted into the opening of an associated one of the plurality of bosses with one end portion extending through and from an associated one of the openings formed in the first wall of the first L- shaped member and with the other end having a portion thereof positioned within one of the plurality of guide notches;

the other ends of the plurality of terminals being aligned in a desired arrangement by the positioning of the portion thereof within the plurality of guide notches; and the second L-shaped member being assembled complementarily with and secured with the first L-shaped member with the other ends of the aligned terminals being inserted through associated ones of the plurality of openings formed in the first wall of the second L-shaped member and an inner surface of the second wall of the second L- shaped member being positioned adjacent to ends of the plurality of bosses to retain the plurality of terminals in the assembled position. 

1. An electrical connector, which comprises: a first preformed insulating member having at least an outer surface and an inner surface; a plurality of terminals; means formed on the inner surface of the first insulating member for supporting intermediate sections of the terminals which are assembled with the first member so that one end portion of each terminal extends from the outer surface of the first insulating member and the opposite end portion of each terminal extends from the means for supporting the terminals; a second preformed insulating member having at least an outer surface and an inner surface and structure complementary to the first insulating member, the second insulating member being assembled with the first insulating member and the terminals to restrict the intermediate sections of the terminals to a position within the means for supporting and to support the opposite end portions of the terminals which extend through the inner surface and beyond the outer surface of the second insulating member to provide interconnecting terminations externally of the assembled first and second insulating members; and means for engaging the opposite end portions of at least some of the terminals to guide the opposite end portions of the terminals into a position of alignment with and for assembly with the second insulating member when the second insulating member is assembled with the first insulating member and the terminals.
 2. The electrical connector as set forth in claim 1, wherein the means for supporting intermediate portions of the terminals includes a plurality of bosses which are formed integrally with the first insulating member and extend from the inner surface of the first member.
 3. The electrical connector as set forth in claim 1, wherein the means for engaging the opposite end portions of the terminals includes a plurality of notches formed selectively in the inner surface of the first insulating member for receiving the opposite end portions of at least some of the terminals to align the opposite end portions in a position for assembly with the second insulating member.
 4. An electrical connector, which comprises: a first L-shaped member composed of an insulating material; a second L-shaped member composed of an insulating material; each of said L-shaped members having first and second walls with each wall having an inner and an outer surface; the first wall of each of the L-shaped members being formed with a plurality of openings; a first plurality of bosses extending perpendicularly from the inner surface of the first wall of the first L-shaped member and along the inner surface of the second wall of the first member; a second plurality of bosses extending perpendicularly from the inner surface of the first wall of the first insulating member; each of the first and second plurality of bosses formed with an opening which is an axial continuation of one of the openings formed in the first wall of the first L-shaped member; a first plurality of guide slots formed in the inner surface of the first wall of the first L-shaped member aligned with and spaced from the first plurality of bosses; a second plurality of guide slots formed in the second plurality of bosses in communication with the openings of the bosses; a first plurality of terminals, each of the first plurality of terminals having an intermediate portion inserted into the opening of an associated one of the first plurality of bosses with one end portion extending through and from an associated one of the openings formed in the first wall of the first L-shaped member and with the other end having a portion thereof positioned within one of the first plurality of guide slots; a second plurality of terminals, each of the second plurality of terminals having intermediate portions inserted into the opening of an associated one of the second plurality of bosses with one end portion extending through and from an associated one of the openings formed in the first wall of the first L-shaped member and with the other end having a portion thereof positioned within one of the second plurality of guide slots; the other ends of the first and second plurality of terminals being aligned in a desired arrangement by the positioning of the portion thereof within the first and second plurality of guide slots, respectively, and the second L-shaped member being assembled complementarily and secured with the first L-shaped member with the other ends of the aligned terminals being inserted through associated ones of the plurality of openings formed in the first wall of the second L-shaped member and the inner surface of the second wall of the second L-shaped member being positioned adjacent to ends of the first and second plurality of bosses to retain the first and second plurality of terminals in the assembled position.
 5. AN electrical connector, which comprises: first and second complimentarily formed, L-shaped insulating members, each member having first and second walls with a plurality of openings formed in the first walls thereof; a plurality of bosses extending perpendicularly from an inner surface of the first wall of the first L-shaped member and along an inner surface of the second wall of the first member; each of the plurality of bosses formed with an opening which is an axial continuation of one of the openings formed in the first wall of the first L-shaped member; a plurality of guide notches formed in the inner surface of the first wall of the first L-shaped member aligned with and spaced from the plurality of bosses; a plurality of terminals, each of the plurality of terminals having an intermediate section inserted into the opening of an associated one of the plurality of bosses with one end portion extending through and from an associated one of the openings formed in the first wall of the first L-shaped member and with the other end having a portion thereof positioned within one of the plurality of guide notches; the other ends of the plurality of terminals being aligned in a desired arrangement by the positioning of the portion thereof within the plurality of guide notches; and the second L-shaped member being assembled complementarily with and secured with the first L-shaped member with the other ends of the aligned terminals being inserted through associated ones of the plurality of openings formed in the first wall of the second L-shaped member and an inner surface of the second wall of the second L-shaped member being positioned adjacent to ends of the plurality of bosses to retain the plurality of terminals in the assembled position. 